Method for splicing webs

ABSTRACT

A method and apparatus for removing an imperfect portion of a web to form trailing and leading web portions, and splicing the web portions to form a continuous perfect web. The apparatus comprises a pair of fixed, spaced apart knife blades adjacent separate perfect and imperfect web paths, and a moveable knife blade cooperating with the fixed knife blades in succession for severing the web at opposite ends of the imperfect portion to form a trailing web end portion lying in the perfect web path and a leading web end portion lying in the imperfect web path. A web guiding member is coupled to the movable blade for selectively guiding the web along the perfect and imperfect web paths. When the movable blade is returned to its normal position, the web guiding member moves the leading web end portion to the perfect film path in position to be spliced to the trailing web end portion.

March 26, 1974 M. w. KRON METHOD FOR SPLICING WEBS 3 SheetsSheet 1v Filed Sept. 20, 1972 March 26, 1974 M. w. KRON METHOD FOR SPLICING WEBS 5 Sheets-Sheet 2 Filed Sept. 20, 1972 March 26, 1974 w, KRQN METHOD FOR SPLICING WEBS 3 Sheets-Sheet 8 Filed Sept. 20, 1972 United States Patent 3,799,826 METHOD FOR SPLICING WEBS Martin W. Kron, Rochester, N.Y., assignor to Eastman Kodak Company, Rochester, N.Y. Filed Sept. 20, 1972, Ser. No. 290,605 Int. Cl. G03d 15/04; B29e 27/04 US. Cl. 156-159 5 Claims ABSTRACT OF THE DISCLOSURE A method and apparatus for removing an imperfect portion of a web to form trailing and leading web portions, and splicing the web portions to form a continuous perfect web. The apparatus comprises a pair of fixed, spaced apart knife blades adjacent separate perfect and imperfect web paths, and a movable knife blade cooperating with the fixed knife blades in succession for severing the web at opposite ends of the imperfect portion to form a trailing web end portion lying in the perfect web path and a leading web end portion lying in the imperfect web path. A web guiding member is coupled to the movable blade for selectively guiding the web along the perfect and imperfect web paths. When the movable blade is returned to its normal position, the web guiding member moves the leading web end portion to the perfect film path in position to be spliced to the trailing web end portion.

BACKGROUND OF THE INVENTION Field of the invention This invention relates generally to cutting mechanisms, and more specifically to an improved method and apparatus for removing an imperfect portion of a web to form trailing and leading web end portions, and placing the web end portions in position for splicing to form a continuous perfect Web.

Description of the prior art A method and apparatus for removing an imperfect portion of a web is known in the art and described in US. Pat. No. 2,047,221. In this patent, indentations are placed in the web on opposite ends of an imperfect portion, and shifting means is responsive to the lead indentation for shifting the discharge chute to direct the imperfect portion along a different path, thereby eifecting a sorting of the perfect and imperfect articles. Although such a sorting mechanism operates satisfactorily for sorting a web into stacks of perfect and imperfect articles, it is unsuitable for use in an application where an imperfect portion of a web is removed from the web, and the remaining web ends spliced together to form a continuous perfect web. Applicants improved severing mechanism has the advantage of removing an imperfect portion from a web and automatically repositioning the web ends in position to be spliced together.

SUMMARY OF THE INVENTION A method and apparatus is disclosed for removing an imperfect portion of a web to form trailing and leading web end portions, and placing the web end portions in position to be spliced together. In accordance with a preferred inventive method, perfect and imperfect web paths are defined, and a web having an imperfect portion is transported along the perfect web path. The web is severed on one side of the imperfect portion to form a trailing web end portion lying in the perfect web path, and the imperfect portion is transported and guided along the imperfect web path. The web is severed on the opposite side of the imperfect web portion to remove the imperfect portion from the web and form a leading web end por- Patented Mar. 26, 1974 tion lying in the imperfect web path. Then'the leading web end portion is returned to the perfect web path in position to be spliced to the trailing web end portion. In accordance with a preferred embodiment of the severing apparatus for practicing the inventive method, means are provided for defining perfect and imperfect web paths. A first fixed severing means is arranged adjacent the perfect web path, and a second fixed severing means'is spaced from the first severing means and arranged adjacent the imperfect web path. A third severing means is arranged for movement between initial and fixed positions, and is 'cooperable with the first and second severing means for severing a web in the perfect and imperfect web paths. Web guiding means is coupled to the third severing means for movement between a first position in which it guides a web having an imperfect portion along the perfect web path, and a second position in which it guides a web having an imperfect portion along the imperfect web path. The web guiding means is further responsive to the third severing means for returning the leading web end portion lying in the imperfect Web path to the perfect web path in position to be spliced to the trailing web end portion. In a further feature of the invention, the coupling between the third severing means and the web guiding means is in the form of lat'ch means. In a more specific feature of the invention, a resilient stop means is provided for the web guiding means to permit relative movement between the web guiding means and the third severing means for altering the coupling therebetween so that it is assured that the leading web end portion will clear the first severing means and rest in the perfect web path.

The primary advantage of applicants method and apparatus of this invention is to provide an automatic, reliable, time and cost saving system for removing an imperfect portion of a web to form trailing and leading web end portions, and placing the web end portions in position ot be spliced together to form a continuous perfect web.

One of the objects of the present invention is to provide a method and apparatus for automatically removing an imperfect portion from a web to form trailing and leading web end portions, and splicing the web end portions together to form a continuous perfect web.

Another object of the invention is to provide a method and apparatus for removing an imperfect portion of a web that is of simple design and construction, thoroughly reliable and efficient in operation, and economical to manufacture.

The invention and its objects and advantags will become more apparent from the detailed description of the preferred embodiment presented below.

BRIEF DESCRIPTION OF THE DRAWINGS In the detailed description of the preferred embodiment of the invention presented below, reference is made to the accompanying drawings, in which:

FIG. 1 is a segmental, side elevational view of the severing apparatus of this invention with a side frame removed for purposes of clarity;

FIG. 2 is an elevational view of the severing apparatus of FIG. 1 taken substantially along line 2-2 of FIG. 1;

FIG. 3 is a segmental, plan view of the severing apparatus of FIG. 1 taken substantially along line 3-3 of FIG. 1;

FIG. 4 is a segmental view of the severing apparatus of FIG. 1 with portions thereof omitted for purposes of clarity, and illustrating one position of the movable blade severing the leading end of an imperfect portion and directing the imperfect portion and web into the imperfect web path;

FIG. 5 is a segmental view similar to FIG. 4 illustrating the movable blade in a position severing the imperfect portion along the imperfect web path; and

FIG. 6 is a view similar to FIG. 4 illustrating the movable blade of the apparatus in its normal position, and a pivotal trap door carried thereby in a position in which the leading web end portion has been moved past a fixed blade for movement onto the surface of the perfect web path.

DESCRIPTION OF THE PREFERRED EMBODIMENT Because severing and splicing mechanisms are well known, the present description will be directed in particular to elements forming part of, or cooperating more directly with, apparatus in accordance with the present invention. Severing and splicing elements not specifically shown or described herein should be understood to be selectable from those known in the art.

With reference to the drawings, a severing apparatus 8 is illustrated for removing an imperfect portion of a web 10 to form trailing and leading web end portions, and placing the web end portions in position to be spliced together to form a continuous perfect web. Although such a severing apparatus has utility in any application in which it is desired to remove imperfect portions of a material from the remainder of the material, it is particularly useful in a slitter-spooler of the type partially shown in FIG. 1 in which a wide roll of web material is slit by a slitter, not shown, into a plurality of webs of narrower width, and the narrower webs rewound on spools, not shown. In such a slitter-spooler, it is desirable to remove any imperfect portions in each of the narrower webs by transporting each web through a severing apparatus 8, and to splice the remaining web ends together of each web to form a continuous perfect web for winding on a spool. To accomplish this, web transport means such as pinch rollers 12 and drive control means, not shown, is provided for each of the webs to transport the web through its corresponding severing apparatus along a perfect web path and onto a spool. Any suitable sensing means, not shown, may be provided for sensing the leading end of an imperfect web portion, and in response thereto actuating a severing apparatus 8 through any suitable air cylinders, valves and electrical control system causing the apparatus to move to a first position (FIG. 4) in which a movable blade mechanism 14 cooperates with a fixed blade 16 for severing web 10 before the defective portion, leaving a leading web end portion lying in the perfect web path. In addition, blade 14 directs the imperfect portion and web 10 into an imperfect web path. After the web transport means 12 has transported web 10 including the imperfect portion along the imperfect web path a sufficient distance until the trailing end of the imperfect portion is past a fixed blade 18, the severing apparatus 8 is again actuated by the control system causing the apparatus to move to a second position (FIG. 5) v in which movable blade mechanism 14 cooperates with blade 18 for severing the imperfect portion from web 10. The movable blade mechanism 14 is then returned by the control system to its normal position, and while doing so moves a web guiding trap door 20 coupled thereto to a position urging the leading end portion 22 of the web from the imperfect'web path into the perfect web path adjacent the trailing web end portion 15 and in position for splicing. A splicing mechanism of any suitable type such as an ultrasonic horn 24 is moved into engagement with web end portions 15, 22 for splicing the web ends together to form a continuous perfect web. The web transport rollers 12 are again actuated for transporting web 10 through severing apparatus 8 and onto the take-up spool. The take-up spool may be driven by any suitable drive motor and clutch arrangement, not shown, for winding the perfect web on the spool.

More specifically, in accordance with a preferred embodiment of the invention, movable blade mechanism 14 comprises a U-shaped blade holder 26 in which the ends thereof are secured to shafts 28 journaled for rotation inside frame members 30 of the slitter-spooler. A shear blade 32 is secured by any suitable means to the blade holder 26, and holder 26 and blade 32 are pivotally movable about axis 34 by any suitable air cylinder 36 or the like, one end of which is pivotally secured to holder 26 by a pin 38.

A bed 40 is mounted on the top of frame members 30, and web 10 is transported on the upper surface of bed 40 from the slitter through severing apparatus 8 and onto the take-up spool, not shown. Fixed blade 16 extends across frame members 30 with the upper surface thereof lying substantially in the plane of bed 40, and is of length at least equal to the width to the web to be severed. Also supported by frame members 30 is fixed blade 18 spaced from blade 16 to form a passageway therebetwen through which, when desired, an imperfect portion of the web is transported and guided along an imperfect web path. Blade 18 also spans frame members 30 and is of a length at least equal to the width of a web to be severed. The fixed blades 16, 18 are arranged in cutting relation to moving blade 32 such that the moving blade when pivoted from its normal position seen in FIG. 1 to its lowermost position seen in FIG. 5 will sever in succession web 10 interposed between blade 32 and each of the fixed blades 16, 18 respectively. Preferably, movable blade 32 is secured to holder 26 in non-parallel relationship to fixed blades 16, 18 for improved cutting action.

As indicated earlier, the web guiding trap door 20 coupled to movable blade mechanism 14 serves the purpose in FIG. 1 of guiding a perfect web through severing apparatus 8, in F-IGS. 4 and 5 of guiding the imperfect web portion along the imperfect web path, and in FIG. 6 of lifting the leading web end portion 22 from the imperfect web path to the perfect web path in position for splicing. In addition, trap door 20 serves to pinch the leading web end portion 22 against the undersurface of blade 32 as seen in FIG. 5 to prevent inadvertent transport of web 10 past blade 32. The trap door 20 has a substantially rectangular body member 42 (FIG. 3) extending into a cut-out portion 44 in bed 40, and has legs 46 extending from each side provided with stub shafts 48 journaled in the frame. Accordingly, trap door 20 is pivotally movable about pivot 50 (FIG. 1) from a normal position, as best seen in FIG. 1, in which the upper surface of trap door 20 lies in the plane of bed 40 and supports web 1 0 transported over the bed and through the severing apparatus. The trap door 20 is held in this normal position by latch means comprising a hook 52 at one end of a lever 54 secured to blade holder 26. The hook 52 engages the end of a spring finger 56 supported by body member 42 and extending through slot 58 as best seen in FIGS. 1 and 3. Accordingly, when holder 26 and blade 32 are pivotally moved from their normal position (FIG. 1) to a first position as seen in FIG. 4 for severing web 10 just prior to a defective portion, the pivotal trap door 20, due its weight, follows lever 54, and the upper surface thereof forms a support and guide for the defective portion of the web. Further movement of blade 32 to a second position in cutting relation with lower blade 18 for severing the imperfect web portion, as best seen in FIG. 5, causes the lower surface of trap door 20 to engage a roller 60 on the end portion of a U-shaped spring 62 secured to the frame for releasably holding trap door 20 as holder 26 and lever 54 are moved relative thereto causing spring finger 56 to ride along the surface of the lever and past a shoulder 64 formed thereon. The upper surface of trap door 20 pinches leading end 22 the web against blade 32 to prevent inadvertent web transport by the transport rollers 12. When the blade holder 26 and blade 32 are returned to their normal position as seen in FIG. 6, lever shoulder 64 engages spring finger 56 and lifts trap door 20 to a position in which its upper surface is above the surface of bed 40 to assure that web end 22 carried thereby will clear blade 16. At this time, a pair of pusher fingers 66 shown dotted in FIG. 1 which are reciprocally movable by an air cylinder are moved into engagement with the upper surface of the trap door 20, depressing it causing spring finger 56 to slide off shoulder 64 and trap door 20 to drop into its normal position as seen in FIG. 1 with spring finger 56 engaging hook 52. Since the pivot point 50 of trap door 20 is offset from pivot point 34 of blade holder 26, it is assured that spring finger 56 will be engaged by shoulder 64 when blade holder 26 is moved from the position shown in FIG. 5 t the position shown in EIG..6. To assure that web end 22 moved upwardly by trap door 20 will extend past the cutting edge of upper blade 16 to provide web end overlap for splicing, the pivot point 34 to blade holder 26 is located a short distance below the upper surface of bed 40. To further assure overlap of the web ends 15, 22, any suitable web support means such as a shoulder 68 may be provided between the pivot 34 of blade holder 26 and lower blade 18. Such a support means over which the web is transported extends the length of the web to lower blade 18. To minimize interference between web end portions 15, 22 as they are overlapped, bed 40 is provided with a notch 70 or depression adjacent upper blade 16 and preferably extending across the width of the bed. A reciprocally movable shoe 72 is supported by frame 30 and is adapted when moved by a cylinder 74 to press web 10 into notch 70 causing the trailing end 15 of the perfect web to be lifted up as seen in FIG. 6. This assures that the leading end portion 22 of the web will move under the lifted trailing web end portion 15 when it clears upper blad 16. In this position as seen dotted in FIG. 6, the leading and trailing web end portions 15, 22 are in overlapped relation, and in position to be spliced together by reciprocally movable ultrasonic born 24 in register therewith. When the splice is completed, the web 10 is again transported by the transport rollers 12 over the perfect web path onto the take-up spool.

If the imperfect portion is of substantial length, the control system of the severing apparatus may be modified in a known way causing the air valves and electrical control system to actuate air cylinder 36 for reciprocally moving holder 26 and blade 32 rapidly and repetitively between the positions shown in FIGS. 4 and during web transport for chopping the imperfect web portion into scrap pieces of short length.

The invention has been described in detail with particular reference to a preferred embodiment thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention as described herein above.

I claim:

1. In a method for removing an imperfect portion of a web to form trailing and leading perfect Web end portions and placing the web end portions in position to be spliced together to form a continuous perfect Web, comprising the steps of:

defining perfect and imperfect web paths;

transporting a web having an imperfect portion along said perfect web path;

severing said web on one side of said imperfect portion to form a trailing web end portion lying in said perfect web path; transporting and guiding said severed web having said imperfect portion along said imperfect web path;

severing said web on the other side of said imperfect web portion to remove said imperfect portion from said web and form a leading web end portion lying in said imperfect web path; and

returning said leading Web end portion to said perfect web path in position to be spliced to said trailing web end portion.

2. The method according to claim 1, and further comprising the step of splicing together said trailing and leading web end portions.

3. The method according to claim 1, and further comprising the step of severing said imperfect portion into a plurality of pieces.

4. The method according to claim 1, and further comprising the step of overlapping the ends of said trailing and leading web end portions in said first path.

5. The method according to claim 1, and further comprising the step of providing a first severing station adjacent said first path, and a second severing station adjacent said second path.

References Cited UNITED STATES PATENTS 3,627,616 12/1971 Davis 156-502 3,654,034 4/ 1972 Hermle et al. 156-502 3,642,555 2/1972 Nagoshi et al. -156505 3,519,507 7/1970 Pierson 156-49 WILLIAM A. POWELL, Primary Examiner B. J. LEI'ITEN, Assistant Examiner us. c1. xn. 

